Electrolytic reduction cell for producing aluminum



C. S. THAYER Feb. 17, 1959 ELECTROLYTIC REDUCTION CELL FOR PRODUCING ALUMINUM 2 Sheets-Sheet 1 Original Filed Aug. 12, 1950 INVENTOR.

ATTORNEY Feb. 17, 1959 4 c. s. THAYER ELECTROLYTIC REDUCTION CELL FOR PRODUCING ALUMINUM 2 Sheets-Sheet 2 Original Filed Aug. 12

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Charles S. Thoyer ATTORNEY I moltenbath 3' layer,- is so near ELECTROLYTIC REDUCTION CELL FOR PRODUCING ALUMINUM Wash., assignor to Alumi:

Charles S Thayer, Vancouver,

Pittsburgh, Pa., :1 corpora num Company of America, tion of Pennsylvania This invention relates in general to the constructi'on and operation of electric furnaces, cells or pots suitof a fused salt bath. This application is a division'of my application, Serial No. 179,037, filedAu'gust 12, 1950, now Patent No. 2,824,057. p

It is a well-known fact that a conductor carryingelectrio current produces a-magnetic field surrounding it and that the direction of the field bears a definite-relat tionship to the direction of the current within the con ductor. The direction of the magnetic field is determinable by the thread rule; that is, itis the same as the direction of rotation of a screw; thread, when the screw is turned toaxially move the same in the direction of current flow. The intensity of the magnetic field at any point'is proportional to the in-. tensity of the current flow in the conductor and inversely proportional to the distance consideration and the current-carrying conductor. a

It is an equally well-known factthat a forceis exerted onxa conductor carrying an electric current 'ina magnetic field provided the field has a directional co'r'npo nent at right angles to the bow of current; The force tends to move theconductor .atright angles to the direction of both the current and the component of the magnetic-field lines at right angles to 'the' eurrent. The direction of the force exerted on a conductor isreadily= determinable .by the left hand rule,"' where theiridex finger is pointed in the direction of current flow in the conductor, the thumb at right angles'to the index'finger is pointed in the direction of the magnetic field,.andthe second, finger at right angles to the thumb and'index finger is. pointed in the direction of the'force exerted on The intensity of the force exerted upon.

the conductor. a conductor carrying current in, a magneticfield is pro portional to the intensity of c'urrentflow in the conductor, the intensity of the component of thexmagnetic field at right angles to the conductor and. theilength of vthe path of flow of the current within the magnetic: field. I

,These; principles apply whether the electrical conductor be-solid or liquid. In the case of fluid-or liquid conductors,v such as a molten metal pad or 'pool carryingan electric current withinlanelectrolyticf cell,'xany external: magnetic, field acting at 1 right angles to theidirection of flow of the current reacts to'set the molten-metal coneductors in motion, which may result. in circulation ofthe liquid-conducting phase inthe apparatus' confiniug the same and cause a departuretrom surface of the molten metal. This. motion andqcirculaa tion is known as' rnotor effect" and the development ofi uneven, more or less stationary crests molten metal .phase within the apparatus is termed-metal P P-. r In the electrolytic, production of aluminum', the specific. gravity: oi the, molten, metal -layer, lying beneath the? the latter that the, force required to.produce;,"fpile-up; of:

the metal is much less than it would be if the metal layer in the conductingto the specific gravityof nitfid SUUZQ Patent p v 2,874,110 Patented Feb. 17, rese- 2 was in air; since the forcetending to level off the metal surface is only that due to the difierence between the specific gravities (metal spxgl- -bath sp. g.) i nstead t that due to the difference between the specific gravity of the metal and that of the air.

This metal pile-up is seriously objectionable as it causes considerable variatlon in the distance between .reducing the efiiciency of the cell. also 'a' condition which, in

anode and'cath'ode, over the surface of the metal cathode (pool) ,-"-a 'n'd may even cause 'the' molten metal to touch an anode 'and produce a partial short "circuit, thus Metal pile-up is practice, limits theanodecathode distance, sothat the latter cannot be made as small as would tie-desirable forf'the purpose of reducing the voltage st in forcing the current through the bath,

r and thus reducing the'power consumed per pound of able for the production of alummum-by the electrolys s having a; right hand f trate my'inventien} in which:

metal produced; Power is a-very important item of cost in the production of aluminum, and a reduction in the power required per pound f metal means a definite reduc'ti'on'in costjand hence is most desirable.

The drawings, forming a part hereof, will serve o illusbeen incorporated; and

between the point under Fig. 7 represents-a single'an'ode cell otherwise similar toFig.5. m

'The invention-is directed in general to'the provision of electrically conducting,resistanceheated apparatus with molten contents, such as'f'electr ol'yti'c reduction cells for an. otherwise level,

the production ofj'rnetall'c aluminum from alumina. In rno're 's'pecific terms; the invention relates to electrolytic reductioncells in which the direction and intensity of the magneticfields developed by the anode and cathode conductors serving the cells", as well as the direction and intensity of the electric currents carried thereby and throughthe' molten 'c'athode contents of the cells, are controlled by proper' sele'ction and disposition of cathode collector bar arrangements, embedded within the bottoms Of" tIf1 C6llS,' in respect to their physicalrelation'ship to cathode bus bars in electrical connection with the embedded" collector bars. v

Referring-'tolthe illustrations, and in particular lfigs. 1 and 2, aftypical' electrolytic cell or, pot, suitablefor the manufacture offrnetallic 'aluminum from its oxide, is

shown in perspective and "sectionalelevation, respectively.

It will 'be'fibserved' that-the, cellc'omprises in its essential elementsg'amouter steel shell 10 having 'an "inner electrically-conductivecarbon lining 1-2 ,-and' an intermediate' heatand electrical insulating barrier 14'.) The lining from prebaked' carbon blocks or ieafteribalgedi; The, heatinsulatg barrier" ll'fma'y-" beconstructed fromfsuitable fire brick-for shedirisulating'ihaterial? Q "Anys'urtab e anodesls", "for flintroducing electric'ourrear-Tare srip erreaqabove the cell and dependi downlay'enofelectrolyte 16'Which, be-

wardlyinto "an upper cause of its lowerspecific gravity, floats or rests upon' ni-ohthe cell cavityPThe anodes 15 are preferably 'rect'angular' carbon'blocks and are supported i'n' such 'a n aaaer (not specifically illustrated) that they ar readily adjustable vertically to maintain proper anodecathode; distance between the normally flafunderside ofthe anodes 15andthe-molten metal pad '18."

Anydesirediarrangement of electrical conductors may be employed to supply current to the anodes, an aluminum or copper bus bar 20, and similar bus bars 22 leading to each of the rows of carbon anodes 15, being here illustrated for this purpose. Electrically-conductive bars or rods 24 of copper not only serve to conduct electric current to the anodes 15, but also to support the same from above the cell. I

In the normal operation of the cell thus far described, a fused electrolyte of dissolved alumina in cryolite,; represented by the layer 16, electrolyzed by the flow of direct current supplied through. the anode system, and the alumina charge is electrolytically reduced to molten metallic aluminum which collects in the bottom of the cell, as represented by the pad or pool 18. V

It has been common practice to complete the current circuit through a cell of the type above described by means of a cathode system comprising, in general, the molten metal cathode 18, conductive carbon lining .12 and horizontal collector bars '25 embedded within the carbon lining 12 below the molten metal cathode. 18. Collector bars 25, embedded in the carbon lining 12 beneath the respective rows of anodes15, normally extend laterally throughthe shell on either side of the cell. The protruding exterior ends of the collectors 25, which are preferably steel :or ironbars, are suitably connected by cathode conductor bars 26, of copper, to an aluminum or copper cathode bus bar 28.. p

In a commercial installation, it is normal practice to arrange a large number of cells or pots in single or multiple tandem rows, in which case the cells areelectrically connected in series, with the cathode bus bar 28 ofone pot discharging its current into the anode bus bar 20 of the next succeeding pot in the line.

Depending on the direction anddensity of currents within the liquid conductors and the distribution and strength of the magnetic fields within the pot cavity, the motor efiects may be quite vigorous in-cells of the type described herein and illustrated in Figs. 1 and 2. Some motion in the bath, which serves to stir it and distribute additions of alumina throughout the fused cryolite during continued operation of a cell, is desirable. However, under the relatively high operating; currents (30,000 to 50,000 amperes) employed in cells. of the type under discussion, too vigorous agitation of .the fluid charge. (electrolyte 16, and especiallvmolten metal pad 18) within the cell, and resultant pile-up of the metal pad 18, has been found to give ineflicient pot operation, as heretofore described. I

In acell constructed as shown in Fig.1, the currents carried by buses 22 and 26 set up magnetic fields within the cell cavity containing the molten bath 16 and molten metal pad 18. The fields set up by the bus bars 22 have a generally horizontal direction :within the cavity, parallel to the direction of the collector bars 25, while the fields set up by the bus bars 26 have a generally vertical direction in the cavity. All currents flowing within the cell itself and adjacent to it set up their re-. spective magnetic fields. The actual magnetic field direction and strength at any point is .the resultant of all magnetic fields having an influence at that point.

In the cell shown in Figs. 1 and :2, the currents which flow in a vertical direction in the liquid conductors within the cell (bath 16 and metalIS) are ofrelatively low current density and are of short length. Consequently, under the given magnetic conditions, the force causing motion due to their interaction with the magnetic field, is relatively small. I j

The current passing through the cell, from the anodes to the cathode bus 26, divides itself so as to'occupy all possible paths, in inverse proportion to the .electrical resistance of such paths. The molten aluminum has v by far the lowest specific resistance of the materials through: which the current flows, and when a moderately thick layer is present, the cross section presented for a'horizon-' tal flow of current is very large. Jlaking into'co'nsidera- 7 minimum the vertical, component of the but is progressively tion the relatively high current density in the steel collector bars 25 and the large cross section of the carbon lining 12 as compared with that of the collector bars, it is evident that the path of least resistance is nearly vertically down from the anode to the molten metal pool, then to some extent horizontally toward the side of the cavity, and thence downward into the collector bars, as diagrammatically indicated in Fig. 2. The dimensions of commercial aluminum cells are such that the density of current flowing horizontally in the metal may be relatively high and the length of path relatively long, as compared with the density and length of path of the vertical currents. Such horizontal flow of current in the molten'metal, lying in a vertical magnetic field, imparts to the metal a motion which is a function of current and field strengths and directions. Under some conditions this motion is of such intensity as to seriously interfere with eflicient and satisfactory operation of the cell.

Horizontal fields parallel to the current flow have no effect, and horizontal fields at right angles to the current fiowa relatively small one.

It is found by experience that the horizontal flow of the current in a vertical magnetic field is the principal cause of the objectionable motion in the metal. By increasing the thickness of the metal pad the current density 'in the horizontal flow can be reduced, and this reduces somewhat the metal motion and pile-up.

For minimum motion it is necessary to reduce to a magnetic field passing through the molten aluminum. This vertical component is chiefly due .to the current in the parallel us bars 26 and is particularly great at the rear of the pot, because of the increase in current density in bus bars 26 as they approach the rear of the pot, and the effect of the piece of bus 28 passing across the rear end of the pot. This effect can be minimized by arranging-matters so that both these bus bars 26 carry the same amount of current; in which case, since they are parallel conductors carrying current in the same direction, their fields tend to partly neutralize each other in the space between them. In fact this neutralization is approximately complete near the center of this space, less complete as either side of the cavity is, approached. If the cell cavity shown in Figs. 1 and 2 is narrow, as compared with the total distance between the bus bars 26, the mutual neutralization of the two fields may 'bepnearly complete throughout the cavity. If, however, a wider cell cavity is employed, as is necessary in large cells, the neutralization is incomplete and a substantial vertical component of electromagnetic field remains near the sides of the cavity. In such a case, additional means may need to be employed to minimize the "electromagnetic motion of the molten aluminum.

7 The remaining available means for reducing electromagnetic motion of the molten aluminum is to reduce the length of the path of horizontal flow of the current. within'the molten aluminum, and if necessary to reduce such horizontal flow to zero; that is, to cause the current flow to' be substantiallly vertically downward through the molten metal into the lining 12 of the cell and intothe' collector bars 25. This may be accomplished by a'suitable arrangement or design of the collector bars. 'Anumber of arrangements for accomplishing this result are shown in Figs. 3 to 7, inclusive. 1 In Fig. 3% embodiment of the invention is illustrated relatively in'which cathode collector bars 44 are disposed in direct I lector bar 44 is bent electrical contact and communication with the cathodecarrying, electrically-conducting carbon lining 12 for the portion of their length immediately below the anodes 15. The remainder of the length of each cathode coldownwardly and outwardly into and through the non-electrically-conducting insulation 14 into' electricalconnection with the exterior cathode bus bars- 26. Y

.bodiments of the invention,

A substantially T-shaped cathode collector barv sys'-. tem is illustrated in Fig. 4. In this embodimentof the invention, the cathode collector bars comprise a horizontal portion 46directly below the anodes embedded in electrical contact with the carbonlining 12. The portions. 460i the bars each form the cross bar or head of a T and the bars otherwise complete the T form through the depending legs '48, shownin full line construction running from substantially the mid point of each of the bars 4 6 and extending downwardly into the non-conducting heat insulation 14. Generally horizontal collector legs 50 extend later'ally through the heat' insulation into electrical connection with the exterior cathode bus bars collector bar construction has proved .very satisfactory in electrolytic.cell operation and is the full equivalent of'fthe cathode collector system illustrated in Fig. 3. The legs 48, shown in dotted line construction adjacent the ends of. collector bars 46, illustrate modified forms of the collector bar system of Fig. 4, which will be described in more detail hereinfater;

It may be desirable to reverse the usual direction of the electromagnetic motion or motor effect in one or more areas of an electrolytic'cell in order to control and/ or eliminate the motor effect. I have accomplished this by employing cathode collector bar systems, as illustrated in Figs. 5 and 6, wherein only those features of design and construction that differ from the previously described cells require consideration. In the two embodiments of the invention shown in Figs. 5 and 6, it will be found that the cathode collector bars not only establish the path of least resistant to current flow in generally vertical lines, but also establish a generally inward current flow towards the central long axis of the pot or cell. This latter feature further eliminates horizontal current sultant interaction with the vertical magnetic fields. In

fact, by establishing not only generally vertical current flow but also a generally inward current flow towards the central long axis of the pot or cell, the force tending to cause motion of the molten aluminum tends to be in the reverse direction from that when the horizontal current flow is'toward the sides of the cell.

In Fig. 5 a cathode system is represented in which a horizontal U-bend is imparted to the individual collector bars. Each of the upper legs 52 of the bars is embedded in the carbon lining 12 directly below the anode 15 on that side of the cell containing the lead off conductor portion 54. From the directional current flow arrows, it will be seen that there is the same general path of least electrical resistance established for current flow from the anodes 15 downwardly and inwardly towards the long axis of the cell into the cathode bars 26.

Referring to Fig. 6 it will be observed that the cathode collector bars 60 have been embedded in the carbon lining 12 to serve as conductors disposed on opposite sides of the long axis of a rectangular cell. Actually this arrrangement provides an X-type or'crossed collector bar system which tends to establish vertically inward electric current flow towards the center of the cell. Conductor portions 62 within the insulating layer 14, and connector portions 64 incorporated in the con tinuous electrical relationship, complete the X-type installation.

In the illustrations and descriptions of the several ema double row of anodes 15 has been illustrated in each instance. This arrangement is quite customary where prebak-ed carbon anodes are employed. The invention, however, has been equally successful in practice with the StSderberg, self-baking electrode where a single anode is generally employed in each cell. A single anode Stiderberg installation is illustrated in Fig. 7, the cathode collector bars 52 beinginstalled in 26. This particular cathode flow to the sides of the cell, with its relining 12 in their'connection to the exterior cathode bus of a collector bar 46, as distinguished from a central bars 26. I p

I It will also'be observed that all of the cathode collector bar systems described above and. illustrated in Figs. 3 to 7, inclusive, have been so designated and installed as to insure maximum verticalicurrent flow between the anodes 15 and the respective cathode collector bars. In respect to Figs. 5 and 6, centrally inward, as well as vertical paths.

the metal layer, and

of current fiow, are established in of the cell has lateral outward current flow to the sides been diminished, it not entirely eliminated.

Referring further to Fig. :4, the dotted line construction of thelegs 48 of the T-form collect-or bar system'is now described. The dotted line construction illustrates alternate locations and connections adjacent either end of the bars 46 for the full line leg 48. Depending on whether the 'leg 48 is located toward or at the inner or outer end connection for the same, either centrally inward, or lateral outward current flow in the metal layer, respectively, will be established. to some degree, in addition to the aforedescri'bed vertical current flow.

It will also be-understood that those electrical conducting portions of the various cathode systems illustrated in Figs. 3 through 7, shown as embedded within the heat insulation layer 14, may if desired be disposed outside the cells. In general, it is preferred to employ iron or steel construction for the cathode collector bar structures hereinabove described.

Having described the invention in terms of several specific embodiments of the same, it is to be understood that it is not to be limited to the specific illustrations,

except insofar as it is defined in the appended claims.

underlying molten aluminum pool, an anode depending downwardiy into the cell cavity and laterally spaced inwardly from the side walls of the-cell cavity, a cathode current-collector system comprising a substantially horizontal cathode bus bar disposed exterior to and adjacent each of two oppositely disposed side walls of the shell parallel to the long axis of the cell cavity, spaced cathode collect-or bars embedded in the electrically-conductive bottom lining in parallel disposition in respect to the bottom surface area of the anode, said embedded cathode collector bars each having current-collecting lengths disposed within and below the top surface of the electricallyconductive bottom lining and confined to substantially the downwardly projected area of the anode above the same, and an electrical conductor for each embedded cathode collector bar connecting its respective cathode collector bar to one of the exterior cathode bus bars, each electrical conductor extending downwardly from its respective cathode collector bar withinthe downwardly projected area of the anode into the insulating material below the bottom electrically-conductive lining and outwardly through the said insulating material in its electrical connection with one of the exterior cathode bus bars. 1

2. An electrolytic cell for producing aluminum from its oxidewhich comprises arectangular open top, shellv length with substantially the downwardly projected sur-' face area of the anode, the leg portion of said T-section below said head portion extending downwardly into an insulating lining within said shell and underlying said bottom carbon lining, and an electrical conductor in electrical conection with the leg portion of said T-section and' a substantially horizontally disposed cathode bus bar located exterior to and adjacent a side wall ofvthe shell, said electrical conductor being embedded within the insulating bottom lining and otherwise out of electrical communication 'with the cell cavity and its contents.

3. An electrolytic cell forproducing aluminum from its oxide which comprises a rectangular open top shell having its side walls and bottom lined with carbon to provide a cavity'in' the cell for receiving a charge of fused electrolyte and underlying molten aluminum 'pad', an anode extending downwardly from above said cell into the cavity, a cathode collector bar having a substantially horizontal current-collecting length embedded within and below the top surface of the bottom carbon lining, said current-collecting length being confined to substantially the downwardly projected area of the bottom surface of the anode, and an electrical conductor connected to an end of the current-collecting length of the embedded cathode collector bar and extending downwardly into an insulating lining underlying the bottom carbon lining of the cell and outwardly therethrough into electrical con-t nectiontwith a substantially horizontally disposed cathode bus bar located exterior to and adjacent a sidewall of the shell, said embedded length of cathode collector bar and electrical conductor constituting a generally U -section disposed substantially horizontally in respect to the downwardly projected bottom surface of the anode.

No references cited.

"electrolyze UNITED STATES PATENT OFFICE CERTIFICATE OF 'CORRECTION atent Nov 2,874,110 February 17, 1959 Charles So Thayer It is hereby certified that error appears in the -printed specification of the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 1, line 37, for "bow" read flow column 3 line 10, before d" insert is. column 5, line '72, after "Soderberg" insert column 6, line 12, for designated read designed line 24,

column '7, line 13, for 'conection" read for "toward" read M towards connection 0 Signed and sealed this 26th day of May 1959.,

(SEAL) Attest: I KARL a, mum ROBERT c. WATSON Commissioner of Patents Attesting Officer 

1. AN ELECTROLYTIC CELL FOR PRODUCING ALUMINUM FROM ITS OXIDE WHICH COMPRISES A SUBSTANTIALLY RECTANGULAR OPEN TOP SHELL HAVING ITS SIDE WALLS AND BOTTOM LINED WITH AN INSULATING MATERIAL AND AN ELECTRICALLY-CONDUCTIVE LINING SUPPORTED ON THE BOTTOM INSULATING MATERIAL TO PROVIDE A CELL CAVITY FOR CONFINING A CHARGE OF FUSED ELECTROLYTE AND UNDERLYING MOLTEN ALUMINUM POOL, AN ANODE DEPENDING DOWNWARDLY INTO THE CELL CAVITY AND LATERALLY SPACED INWARDLY FROM THE SIDE WALLS OF THE CELL CAVITY, A CATHODE CURRENT-COLLECTOR SYSTEM COMPRISES A SUBSTANTIALLY HORIZONTAL CATHODE BUS BAR DISPOSED EXTERIOR TO AND ADJACENT EACH OF TWO OPPOSITELY DISPOSED SIDE WALLS OF THE SHELL PARALLEL TO THE LONG AXIS OF THE CELL CAVITY, SPACED CATHODE COLLECTOR BARS EMBEDDED IN THE ELECTRICALLY-CONDUCTIVE BOTTOM LINING IN PARALLEL DISPOSITION IN RESPECT TO THE BOTTOM SURFACES AREA OF THE ANODE, SAID EMBEDDED CATHODE COLLECTOR BARS EACH HAVING CURRENT-COLLECTING LENGTHS DISPOSED WITHIN AND BELOW THE TOP SURFACE OF THE ELECTRICALLYCONDUCTIVE BOTTOM LINING AND CONFINED TO SUBSTANTIALLY THE DOWNWARDLY PROJECTED AREA OF THE ANODE ABOVE THE SAME, AND AN ELECTRICAL CONDUCTOR FOR EACH EMBEDDED CATHODE COLLECTOR BAR CONNECTING ITS RESPECTIVE CATHODE COLLECTOR BAR TO ONE OF THE EXTERIOR CATHODE BUS BARS, EACH ELECTRICAL CONDUCTOR EXTENDING DOWNWARDLY FROM ITS RESPECTIVE CATHODE EOLLECTOR BAR WITHIN THE DOWNWARDLY PROJECTED AREA PF THE ANODE INTO THE INSUALATING MATERIALL BELOW THE BOTTOM ELECTRICALLY-CONDUCTIVE LINING AND OUTWARDLY THROUGH THE SAID INSULATING MATERIAL IN ITS ELEC TRICAL CONNECTION WITH ONE OF THE EXTERIOR CATHODE BUS BARS. 